-
Contents
-
Table of Contents
-
Bookmarks
Quick Links
Intelligent Tester
CAN VIM
DLC3
2GR-FE ENGINE MECHANICAL – ENGINE
ENGINE
ON-VEHICLE INSPECTION
1.
INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2.
INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3.
INSPECT BATTERY
(a) Inspect the battery (See page CH-4).
4.
INSPECT SPARK PLUGS
(a) Inspect the spark plugs (See page IG-5).
5.
INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
• If any dirt or a blockage remains even after
6.
INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-87).
7.
INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
C110200E02
filter element, clean it with compressed air.
cleaning the air cleaner filter element with
compressed air, replace it.
tester.
Ignition timing:
8 to 12° BTDC at idle
HINT:
Refer to the intelligent tester operator’s manual
for help when selecting the DATA LIST.
EM–1
EM
Summary of Contents for Toyota 2GR-FE
- Manuals
- Brands
- Toyota Manuals
- Engine
- 2GR-FE
Manuals and User Guides for Toyota 2GR-FE. We have 1 Toyota 2GR-FE manual available for free PDF download: Manual
Я езжу на Toyota Vista (50)
Я езжу на Toyota Vista (50)
Здравствуйте. Дорогой автор статьи обновите ссылку на книгу.заранее спасибо!
Ссылку обновил на онлайн версию.
Большой список руководств по ремонту Toyota — t.me/Car_Guide/437
А так же большой выбор:
📚 Руководство по ремонту и эксплуатации авто
📕 Руководства по ремонту грузовых авто
📘 Руководство по ремонту двигателей
📗 Руководства по ремонту грузовых двигателей
⚠️ Электрические схемы
⚠️ Электрические схемы грузовых авто
⚡️ Схемы предохранителей и реле
t.me/Car_Guide/1174
Капиталю движок, мне сказали что оригинальных поршней 3 группы: А, В, С, подбирают под конкретный цилиндр по выработке. Если ни одна из групп не подходит — гильзовки блока тогда. Но я это нигде не могу найти, кто знает про эти группы?
Хорошая тема, но это маленькая часть от техдока(9000стр.) в полном и 2,4 и 3,5
Меня только одно интересует, если есть мануал, реально крутой, какого тут на драйве столько вопросов?
Да не, всё понятно, проще написать тут, чем читать первоисточник 
Какими то загадками говоришь
есть в сети мануал на 9000 страниц. Читай — разбирайся. Но никто не читает. Спрашивают тут.
Напиши почту я тебе пришлю
Note for Owners:
Guidesimo.com webproject is not a service center of Toyota trademark and does not carries out works for diagnosis and repair of faulty Toyota 2GR-FE equipment. For quality services, please contact an official service center of Toyota company. On our website you can read and download documentation for your Toyota 2GR-FE device for free and familiarize yourself with the technical specifications of device.
More Engine Devices:
-
MTD P90 Series
Professional Shop ManualP90 Series Vertical Shaft Engines NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. These materials are intended to provide supplemental information to assist the trained technicia …
P90 Series Engine, 120
-
AGROWATT AWB2-28
SERIE AGROWATT BRUSHLESSManuale di uso e manutenzioneUse and Maintenance manualManuel d’utilisation et de maintenanceBedienungs- und WartungsanleitungenManual de uso y mantenimientoREV0011/2012156725REV0312/2018 …
AWB2-28 Engine, 36
-
MINN KOTA FORTEX
Feature Information ……………………..Assembly …………………………………..Installation ………………………………….Gas Assist Lift Mechanism ……………Operation …………………………………..Adjustments …………………………………Cautions ………………………………………Battery Information ………………………..Batte …
FORTEX Outboard Motor, 28
-
MPI Himax HA2825 Series
Himax Brushless motors are manufactured to high standards for the discerning modeler. Designed for light-weight, highefficiency, and durability these Himax motors are sure to make today’s radio controlled models perform. Please read the entireoperating manual to ensure correct functionality and best performance. The HA2825 series motor is made for small tomedium size models weighing 32 to 64 …
Himax HA2825 Series Engine, 2
Recommended Documentation:
|
2GR-FE ENGINE MECHANICAL – ENGINE |
EM–1 |
ENGINE
ON-VEHICLE INSPECTION
1.INSPECT ENGINE COOLANT
(a)Inspect the engine coolant (See page CO-1).
2.INSPECT ENGINE OIL
(a)Inspect the engine oil (See page LU-1).
3.INSPECT BATTERY
(a)Inspect the battery (See page CH-4).
4.INSPECT SPARK PLUGS
(a)Inspect the spark plugs (See page IG-5).
5.INSPECT AIR CLEANER FILTER ELEMENT SUBASSEMBLY
(a)Remove the air cleaner filter element sub-assembly.
(b)Visually check that there is no dirt, blockage, and/or
|
damage to the air cleaner filter element. |
EM |
|
HINT: |
|
• If there is any dirt or a blockage in the air cleaner |
||
|
filter element, clean it with compressed air. |
||
|
• If any dirt or a blockage remains even after |
||
|
cleaning the air cleaner filter element with |
||
|
compressed air, replace it. |
||
|
6. INSPECT VALVE LASH ADJUSTER NOISE |
||
|
(a) Rev up the engine several times. Check that the |
||
|
engine does not emit unusual noises. |
||
|
If unusual noises occur, warm up the engine and |
||
|
idle it for over 30 minutes. Then repeat this |
||
|
procedure. |
||
|
HINT: |
||
|
If any defects or problems are found during the |
||
|
inspection above, perform lash adjuster inspection |
||
|
(See page EM-87). |
||
|
7. |
INSPECT IGNITION TIMING |
|
|
(a) Warm up the engine. |
||
|
Intelligent Tester |
(b) When using the intelligent tester: |
|
|
Check the ignition timing. |
||
|
(1) Connect the intelligent tester to the DLC3. |
||
|
(2) Enter DATA LIST mode with the intelligent |
||
|
tester. |
||
|
Ignition timing: |
||
|
8 to 12° BTDC at idle |
||
|
CAN VIM |
HINT: |
|
|
Refer to the intelligent tester operator’s manual |
||
|
DLC3 |
||
|
C110200E02 |
for help when selecting the DATA LIST. |
|
EM–2 |
2GR-FE ENGINE MECHANICAL – ENGINE |
|
(c) When not using the intelligent tester: |
|||||||||
|
DLC3 |
Check the ignition timing. |
||||||||
|
CG |
(1) Using SST, connect terminals 13 (TC) and 4 |
||||||||
|
(CG) of the DLC3. |
|||||||||
|
SST |
09843-18040 |
||||||||
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
NOTICE: |
|
|
9 1011 1213141516 |
• Confirm the terminal numbers before |
||||||||
|
connecting them. Connection with a |
|||||||||
|
TC |
wrong terminal can damage the engine. |
||||||||
|
A122830E14 |
• Turn off all electrical systems before |
||||||||
|
connecting the terminals. |
|||||||||
|
• Perform this inspection after the cooling |
|||||||||
|
fan motor is turned off. |
|||||||||
|
(2) Remove the V-bank cover. |
|||||||||
|
Red Lead |
(3) Pull out the red lead wire harness. |
||||||||
|
(4) Connect the tester terminal of the timing light to |
|||||||||
|
Wire |
|||||||||
|
the red lead wire as shown in the illustration. |
|||||||||
|
EM |
NOTICE: |
||||||||
|
Use a timing light which can detect the first |
|||||||||
|
signal. |
|||||||||
|
Tester Terminal |
(5) Check the ignition timing at idle. |
||||||||
|
Ignition timing: |
|||||||||
|
8 to 12° BTDC at idle |
|||||||||
|
A129620E01 |
NOTICE: |
||||||||
|
When checking the ignition timing, the |
|||||||||
|
transmission should be in neutral. |
|||||||||
|
HINT: |
|||||||||
|
Run the engine at 1,000 to 1,300 rpm for 5 |
|||||||||
|
seconds, and then check that the engine rpm |
|||||||||
|
returns to idle speed. |
|||||||||
|
(6) Disconnect terminals 13 (TC) and 4 (CG) of the |
|||||||||
|
DLC3. |
|||||||||
|
(7) Check the ignition timing at idle. |
|||||||||
|
Ignition timing: |
|||||||||
|
12 to 22° BTDC at idle |
|||||||||
|
(8) Confirm that the ignition timing moves to the |
|||||||||
|
advanced angle side when the engine rpm is |
|||||||||
|
increased. |
|||||||||
|
(9) Remove the timing light. |
|||||||||
|
8. INSPECT ENGINE IDLE SPEED |
|||||||||
|
(a) Warm up the engine. |
|||||||||
|
Intelligent Tester |
(b) When using the intelligent tester: |
||||||||
|
Check the idle speed. |
|||||||||
|
(1) Connect the intelligent tester to the DLC3. |
|||||||||
|
(2) Enter DATA LIST mode with the intelligent |
|||||||||
|
tester. |
|||||||||
|
Idle speed: |
|||||||||
|
600 to 700 rpm |
|||||||||
|
DLC3 |
CAN VIM |
NOTICE: |
|||||||
|
• When checking the idle speed, the |
|||||||||
|
C110200E02 |
transmission should be in neutral. |
||||||||
|
• Check the idle speed with the cooling fan |
|||||||||
|
off. |
|
2GR-FE ENGINE MECHANICAL – ENGINE |
EM–3 |
|
DLC3 |
||||||||
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
|
|
TAC |
9 |
1011 1213141516 |
||||||
A122830E15
•Switch off all accessories and air conditioning before connecting the
intelligent tester.
HINT:
Refer to the intelligent tester operator’s manual for further details.
(c)When not using the intelligent tester: Check the idle speed.
(1)Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2)Check the idle speed.
Idle speed:
600 to 700 rpm
9.INSPECT COMPRESSION
(a)Warm up and stop the engine.
(b)Disconnect the injector connectors.
|
13). |
EM |
|
|
(c) Remove the intake air surge tank (See page FU- |
||
|
(d) |
Remove the 6 ignition coils. |
|
|
(e) |
Remove the 6 spark plugs. |
(f)Check the cylinder compression pressure.
(1)Insert a compression gauge into the spark plug hole.
(2)While cranking the engine, measure the compression pressure.
Compression pressure:
1.4 MPa (14 kgf/cm2, 199 psi) Minimum pressure:
0.98 MPa (10 kgf/cm2, 142 psi) Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 15 psi) NOTICE:
•Always use a fully charged battery to obtain an engine speed of 250 rpm or more.
•Check the other cylinders’ compression pressure in the same way.
•This measurement must be done as quickly as possible.
(3)If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again.
HINT:
•If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
•If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
(g)Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
2GR-FE ENGINE MECHANICAL – ENGINE
(h)Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(i)Install the intake air surge tank. (See page FU-17).
10.INSPECT CO/HC
(a)Start the engine.
(b)Run the engine at 2,500 rpm for approximately 180 seconds.
(c)Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d)Check CO/HC concentration at idle and/or 2,500 rpm.
HINT:
Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm).
If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below.
(1)Check A/F sensor and heated oxygen sensor operation.
(2)See the table below for possible causes, and then inspect and repair.
|
CO |
HC |
Problems |
Causes |
|||
|
1. |
Faulty ignitions: |
|||||
|
– |
Incorrect timing |
|||||
|
Normal |
High |
Rough idle |
– Fouled, shorted or improperly gapped plugs |
|||
|
2. |
Incorrect valve clearance |
|||||
|
3. |
Leaks in intake and exhaust valves |
|||||
|
4. |
Leaks in cylinders |
|||||
|
1. |
Vacuum leaks: |
|||||
|
– |
PCV hoses |
|||||
|
Low |
High |
Rough idle |
– |
Intake manifold |
||
|
(fluctuating HC reading) |
– |
Throttle body |
||||
|
– |
Brake booster line |
|||||
|
2. |
Lean mixture causing misfire |
|||||
|
1. |
Restricted air filter |
|||||
|
2. |
Plugged PCV valve |
|||||
|
3. |
Faulty SFI system: |
|||||
|
Rough idle |
– Faulty fuel pressure regulator |
|||||
|
High |
High |
– |
Defective ECT sensor |
|||
|
(black smoke from exhaust) |
||||||
|
– |
Defective MAF meter |
|||||
|
– |
Faulty ECM |
|||||
|
– |
Faulty injectors |
|||||
|
– Faulty throttle position sensor |
||||||
|
2GR-FE ENGINE MECHANICAL – DRIVE BELT |
EM–5 |
DRIVE BELT
|
COMPONENTS |
|
|
V-BANK COVER SUB-ASSEMBLY |
|
|
FRONT FENDER APRON SEAL RH |
EM |
|
V-RIBBED BELT |
|
|
A134931E01 |
|
EM–6 |
2GR-FE ENGINE MECHANICAL – DRIVE BELT |
|
REMOVAL |
||
|
1. |
REMOVE FRONT WHEEL RH |
|
|
2. |
REMOVE FRONT FENDER APRON SEAL RH |
|
|
3. |
REMOVE V-BANK COVER SUB-ASSEMBLY (See |
|
|
page EM-23) |
||
|
4. |
REMOVE V-RIBBED BELT |
|
|
(a) Using SST, release the belt tension by turning the |
||
|
belt tensioner counterclockwise, and remove the V- |
||
|
ribbed belt from the belt tensioner. |
||
|
SST |
09249-63010 |
|
|
SST |
||
|
EM |
||
|
A129622E01 |
||
|
(b) While turning the belt tensioner counterclockwise, |
||
|
align with its holes, and then insert the 5 mm bi- |
||
|
hexagon wrench into the holes to fix the V-ribbed |
||
|
belt tensioner. |
A095070
|
2GR-FE ENGINE MECHANICAL – DRIVE BELT |
EM–7 |
INSPECTION
REPLACE
1. INSPECT V-RIBBED BELT
(a) Visually check the V-ribbed belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the V-ribbed belt.
HINT:
Cracks on the rib side of a V-ribbed belt are considered acceptable.
If the drive belt has chunks missing from its ribs, it should be replaced.
HINT:
|
• A «new belt» is a belt which has been used for |
|||||
|
less than 5 minutes with the engine running. |
|||||
|
• A «used belt» is a belt which has been used for 5 |
|||||
|
CORRECT |
INCORRECT |
minutes or more with the engine running. |
|||
|
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY |
|||||
|
EM |
|||||
|
(a) |
Check that nothing gets caught in the tensioner by |
||||
|
turning it clockwise and counterclockwise. |
|||||
|
A131418E01 |
If a malfunction exitsts, replace the tensioner. |
||||
|
INSTALLATION |
|||||
|
1. INSTALL V-RIBBED BELT |
|||||
|
(a) Install the V-ribbed belt. |
|||||
|
(b) Using SST, turn the belt tensioner counterclockwise |
|||||
|
and remove the bar. |
|||||
|
SST |
09249-63010 |
||||
|
SST |
|||||
|
A129622E01 |
|||||
|
(c) If it is difficult to install the V-ribbed belt, perform the |
|||||
|
Generator |
following procedure: |
||||
|
(1) Put the V-ribbed belt on every pulley except the |
|||||
|
Idler |
tensioner pulley as shown in the illustration. |
|
Water Pump |
(2) While releasing the belt tension by turning the |
|||
|
belt tensioner counterclockwise, put the V- |
||||
|
Tensioner |
ribbed belt on the tensioner pulley. |
|||
|
NOTICE: |
||||
|
• Put the backside of the V-ribbed belt on |
||||
|
Idler |
the tensioner pulley and idler pulley. |
|||
|
• Check that the V-ribbed belt is properly |
||||
|
A/C Compressor |
set to each pulley. |
|||
|
Vane Pump |
(3) After installing the V-ribbed belt, check that it |
|||
|
Crankshaft |
||||
|
fits properly in the ribbed grooves. Confirm that |
||||
|
the belt has not slipped out of the grooves on |
||||
|
A129623E01 |
the bottom of the crank pulley by hand. |
|||
2GR-FE ENGINE MECHANICAL – DRIVE BELT
2.INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52)
3.INSTALL FRONT FENDER APRON SEAL RH
4.INSTALL FRONT WHEEL RH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
|
EM–8 |
2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL |
ENGINE FRONT OIL SEAL
|
COMPONENTS |
||
|
250 (2,550, 184) |
TIMING CHAIN CASE OIL SEAL |
|
|
EM |
V-BANK COVER SUB-ASSEMBLY |
|
|
CRANKSHAFT PULLEY |
||
|
V-RIBBED BELT |
||
|
FRONT FENDER APRON |
||
|
SEAL RH |
||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
||
|
Non-reusable part |
||
|
A134932E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL |
EM–9 |
|
REMOVAL |
||
|
1. |
REMOVE FRONT WHEEL RH |
|
|
2. |
REMOVE FRONT FENDER APRON SEAL RH |
|
|
3. |
REMOVE V-BANK COVER SUB-ASSEMBLY (See |
|
|
page EM-23) |
||
|
4. |
REMOVE V-RIBBED BELT (See page EM-6) |
|
|
5. |
REMOVE CRANKSHAFT PULLEY |
|
|
(a) Using SST, loosen the crankshaft pulley bolt. |
||
|
SST |
SST |
09213-70011 (09213-70020), 09330-00021 |
|
SST |
EM |
|
|
A119083E01 |
||
|
(b) Using SST, remove the crankshaft pulley bolt and |
||
|
crankshaft pulley. |
||
|
SST |
SST |
09950-50013 (09951-05010, 09952-05010, |
|
09953-05020, 09954-05021) |
||
|
SST |
||
|
A119085E01 |
||
|
6. REMOVE TIMING CHAIN CASE OIL SEAL |
||
|
(a) Using a screwdriver, pry out the oil seal. |
||
|
Cut Position |
Protective Tape |
HINT: |
|
Tape the screwdriver tip before use. |
||
|
NOTICE: |
||
|
After the removal, check the crankshaft for |
||
|
damage. If it is damaged, smooth the surface |
||
|
with 400-grit sandpaper. |
||
|
A132241E01 |
|
EM–10 |
2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL |
|
INSTALLATION |
|||
|
Chain Cover |
INSTALL TIMING CHAIN CASE OIL SEAL |
||
|
1. |
|||
|
(a) Apply MP grease to a new oil seal lip. |
|||
|
SST |
(b) Using SST and a hammer, tap in the oil seal until its |
||
|
surface is flush with the timing chain cover edge. |
|||
|
SST |
09316-60011 (09316-00011) |
||
|
NOTICE: |
|||
|
• Keep the lip free of foreign matter. |
|||
|
A132242E01 |
• Do not tap the oil seal at an angle. |
||
|
2. |
INSTALL CRANKSHAFT PULLEY |
||
|
(a) Align the pulley set key with the key groove of the |
|||
|
pulley, and slide on the pulley. |
|||
|
(b) Using SST, install the pulley bolt. |
|||
|
SST |
09213-70011 (09213-70020), 09330-00021 |
||
|
Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf) |
|||
|
EM |
3. |
INSTALL V-RIBBED BELT (See page EM-7) |
|
|
4. |
INSTALL V-BANK COVER SUB-ASSEMBLY (See |
||
|
page EM-52) |
|||
|
5. |
INSTALL FRONT FENDER APRON SEAL RH |
||
|
6. |
INSTALL FRONT WHEEL RH |
||
|
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) |
|||
|
SST |
|||
|
A119084E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL |
EM–11 |
ENGINE REAR OIL SEAL
|
COMPONENTS |
|
|
EM |
|
|
ENGINE REAR OIL SEAL |
|
|
FRONT SPACER |
83 (850, 61) |
|
x8 |
|
|
REAR SPACER |
|
|
DRIVE PLATE AND RING GEAR SUB-ASSEMBLY |
|
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
|
|
Non-reusable part |
|
|
A134930E01 |
|
EM–12 |
2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL |
|
REMOVAL |
|
|
1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY |
|
|
HINT: |
|
|
See page AX-207. |
|
|
2. REMOVE DRIVE PLATE AND RING GEAR SUB- |
|
|
ASSEMBLY |
|
|
(a) Using SST, hold the crankshaft. |
|
|
SST |
09213-70011 (09213-70020), 09330-00021 |
|
SST |
|
|
A129631E01 |
(b)Remove the 8 bolts, front spacer, drive plate and rear spacer.
|
3. REMOVE ENGINE REAR OIL SEAL |
||
|
(a) Using a knife, cut off the oil seal lip. |
||
|
Cut Position |
(b) Using a screwdriver, pry out the oil seal. |
|
|
NOTICE: |
||
|
Be careful not to damage the crankshaft. Tape |
||
|
the screwdriver tip before use. |
||
|
Protective Tape |
||
|
A132244E01 |
|
INSTALLATION |
|||
|
1. INSTALL ENGINE REAR OIL SEAL |
|||
|
(a) Apply MP grease to a new oil seal lip. |
|||
|
(b) Using SST and a hammer, tap in the oil seal. |
|||
|
SST |
09223-15030, 09950-70010 (09951-07150) |
||
|
SST |
Oil seal tap in depth: |
||
|
-0.5 to 0.5 mm (-0.020 to 0.020 in.) |
|||
|
-0.5 to 0.5 mm |
|||
|
Retainer |
|||
|
SST |
|||
|
A132245E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL |
EM–13 |
|
2. INSTALL DRIVE PLATE AND RING GEAR SUB- |
|
|
ASSEMBLY |
|
|
(a) Using SST, hold the crankshaft. |
|
|
SST |
09213-70011 (09213-70020), 09330-00021 |
|
SST |
|
|
A129631E01 |
(b)Apply adhesive to 2 or 3 threads of the mounting bolt end.
|
Adhesive |
Adhesive: |
|
Part No. 08833-00070, THREE BOND 1324 or |
|
|
equivalent |
EM
|
P000601E04 |
|||
|
(1) Install the front spacer, drive plate and rear |
|||
|
1 |
spacer on the crankshaft. |
||
|
5 |
(2) Install and tighten the 8 mounting bolts |
||
|
7 |
|||
|
uniformly in several steps. |
|||
|
3 |
4 |
Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf) |
|
|
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY |
|||
|
6 |
|||
|
8 |
HINT: |
||
|
2 |
See page AX-214. |
||
|
A132243E01 |
|
EM–14 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
ENGINE ASSEMBLY
|
COMPONENTS |
||
|
FRONT WIPER ARM AND |
20 (204, 15) |
|
|
BLADE ASSEMBLY RH |
||
|
FRONT FENDER TO COWL |
||
|
SIDE SEAL RH |
||
|
COWL TOP VENTILATOR |
FRONT WIPER ARM AND |
|
|
LOUVER SUB-ASSEMBLY |
BLADE ASSEMBLY LH |
|
|
EM |
||
|
85 (867, 63) |
||
|
7.5 (77, 66 in.*lbf) |
||
|
5.0 (51, 44 in.*lbf) |
||
|
FRONT FENDER TO COWL |
||
|
SIDE SEAL LH |
||
|
WINDSHIELD WIPER |
||
|
LINK ASSEMBLY |
||
|
COWL TOP PANEL OUTER SUB-ASSEMBLY |
||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
||
|
A134938E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–15 |
|
AIR CLEANER CAP SUB-ASSEMBLY |
|||
|
V-BANK COVER SUB-ASSEMBLY |
|||
|
AIR CLEANER |
|||
|
FILTER ELEMENT |
|||
|
COOL AIR INTAKE DUCT SEAL |
5.0 (51, 44 in.*lbf) |
||
|
5.0 (51, 44 in.*lbf) |
|||
|
AIR CLEANER INLET |
|||
|
ASSEMBLY |
EM |
||
|
AIR CLEANER CASE |
|||
|
RELAY BLOCK |
|||
|
SUB-ASSEMBLY |
|||
|
COVER UPPER |
|||
|
5.0 (51, 44 in.*lbf) |
|||
|
NO. 1 AIR CLEANER INLET |
|||
|
3.5 (36, 31 in.*lbf) |
|||
|
9.0 (92, 80 in.*lbf) |
|||
|
ENGINE UNDER COVER RH |
|||
|
5.0 (51, 44 in.*lbf) |
BATTERY |
||
|
BATTERY TRAY |
|||
|
INTAKE AIR RESONATOR |
|||
|
SUB-ASSEMBLY |
|||
|
ENGINE UNDER COVER LH |
|||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
|||
|
A132994E01 |
|
EM–16 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
FRONT FENDER APRON SEAL RH |
38 (388, 28) |
||
|
V-RIBBED BELT |
|||
|
23 (235, 17) |
|||
|
ENGINE MOVING CONTROL |
|||
|
ROD SUB-ASSEMBLY |
|||
|
9.8 (100, 87 in.*lbf) |
NO. 2 ENGINE MOUNTING STAY RH |
||
|
43 (438, 32) |
|||
|
GENERATOR ASSEMBLY |
NO. 1 FUEL VAPOR FEED HOSE |
||
|
10 (102, 7) |
|||
|
EM |
NO. 1 OIL RESERVOIR |
NO. 1 VACUUM SWITCHING |
|
|
TO PUMP HOSE |
VALVE ASSEMBLY |
||
|
FUEL TUBE SUB-ASSEMBLY |
|||
|
43 (438, 32) |
HEATER INLET WATER HOSE |
||
|
RADIATOR HOSE INLET |
|||
|
RADIATOR HOSE |
|||
|
OUTLET |
|||
|
RETURN TUBE |
|||
|
SUB-ASSEMBLY |
|||
|
NO. 1 OIL COOLER |
NO. 1 FUEL PIPE CLAMP |
||
|
INLET HOSE |
|||
|
25 (250, 18) |
|||
|
HEATER OUTLET WATER HOSE |
|||
|
NO. 1 OIL COOLER |
|||
|
OUTLET HOSE |
CLIP |
||
|
13 (130, 9) |
|||
|
25 (250, 18) |
TRANSMISSION CONTROL |
||
|
COOLER COMPRESSOR ASSEMBLY |
|||
|
CABLE ASSEMBLY |
|||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
Non-reusable part |
||
|
A132995E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–17 |
|
STEERING SLIDING YOKE |
|||
|
FRONT STABILIZER LINK ASSEMBLY LH |
|||
|
35 (360, 26) |
|||
|
TIE ROD ASSEMBLY LH |
EM |
||
|
74 (755, 55) |
|||
|
49 (500, 36) |
|||
|
COTTER PIN |
|||
|
FRONT SPEED |
|||
|
SENSOR LH |
|||
|
8.0 (85, 71 in.*lbf) |
|||
|
FRONT SUSPENSION |
294 (3,000, 217) |
||
|
LOWER NO. 1 ARM LH |
FRONT AXLE HUB NUT LH |
||
|
GASKET |
|||
|
75 (765, 55) |
62 (632, 46) |
GASKET |
|
|
GASKET |
|||
|
56 (571, 41) |
|||
|
62 (632, 46) |
EXHAUST PIPE ASSEMBLY FRONT |
||
|
NO. 1 EXHAUST PIPE SUPPORT BRACKET |
|||
|
33 (337, 24) |
21 (214, 15) |
||
|
EXHAUST PIPE NO. 1 |
|||
|
SUPPORT BRACKET |
|||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
Non-reusable part |
||
|
A132996E01 |
|
EM–18 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
87 (887, 64) |
ENGINE ASSEMBLY |
ENGINE WIRE |
|
|
WITH TRANSAXLE |
|||
|
95 (969, 70) |
|||
|
95 (969, 70) |
|||
|
EM |
VANE PUMP ASSEMBLY |
||
|
NO. 2 FUEL PIPE CLAMP |
|||
|
FUEL TUBE SUB-ASSEMBLY |
|||
|
STARTER ASSEMBLY |
|||
|
43 (439, 32) |
37 (380, 26) |
||
|
FRONT FRAME |
37 (380, 26) |
||
|
ASSEMBLY |
9.8 (100, 87 in.*lbf) |
||
|
7.8 (80, 69 in.*lbf) |
|||
|
FRONT SUSPENSION |
|||
|
MEMBER BRACE |
|||
|
FRAME SIDE RAIL |
REAR RH |
||
|
32 (329, 24) |
PLATE RH |
||
|
85 (867, 63) |
|||
|
32 (329, 24) |
85 (867, 63) |
||
|
FRAME SIDE RAIL PLATE LH |
32 (329, 24) |
||
|
85 (867, 63) |
|||
|
32 (329, 24) |
|||
|
32 (329, 24) |
85 (867, 63) |
FRONT SUSPENSION |
|
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
MEMBER BRACE REAR LH |
||
|
32 (329, 24) |
|||
|
A134929E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–19 |
54 (551, 40)
ENGINE MOUNTING BRACKET RH
DRIVE SHAFT BEARING BRACKET HOLE SNAP RING
FRONT DRIVE SHAFT
DRIVE SHAFT BEARING BRACKET
ASSEMBLY RH
|
64 (650, 47) |
||
|
32 (334, 30) |
EM |
|
|
FRONT DRIVE SHAFT INNER |
||
|
NO. 1 DRIVE SHAFT BEARING |
||
|
LH SHAFT SNAP RING |
||
|
BRACKET SETTING BOLT |
46 (469, 34)
FRONT DRIVE SHAFT ASSEMBLY LH
7.8 (80, 69 in.*lbf)
FLYWHEEL HOUSING
UNDER COVER
64 (653, 47)
43 (438, 32)
|
64 (653, 47) |
EXHAUST PIPE |
|
|
SUPPORT BRACKET |
||
|
41 (413, 30) |
AUTOMATIC TRANSAXLE |
|
|
DRIVE PLATE AND TORQUE |
||
|
ASSEMBLY |
||
|
CONVERTER CLUTCH |
||
SETTING BOLT ENGINE MOUNTING BRACKET FR
N*m (kgf*cm, ft.*lbf) : Specified torque 
Non-reusable part
A134940E01
|
EM–20 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
UNION TO CHECK VALVE HOSE |
||
|
* 21 (214, 15) |
||
|
5.4 (55, 48 in.*lbf) |
||
|
VACUUM HOSE CLAMP |
||
|
* 21 (214, 15) |
||
|
THROTTLE BODY BRACKET |
VENTILATION HOSE |
|
|
EM |
* 21 (214, 15) |
|
|
NO. 1 SURGE TANK STAY |
||
|
16 (163, 12) |
x4 |
NO. 3 WATER BY-PASS HOSE |
|
NO. 2 WATER BY-PASS HOSE |
||
|
INTAKE AIR SURGE TANK |
* 18 (184, 13) |
|
AIR SURGE TANK TO INTAKE MANIFOLD GASKET
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
* DO NOT apply oil
A134939E01
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–21 |
|
8.5 (87, 75 in.*lbf) |
||||
|
EXHAUST MANIFOLD |
||||
|
TO HEAD GASKET |
||||
|
NO. 2 EXHAUST MANIFOLD |
||||
|
HEAT INSULATOR |
||||
|
21 (214, 15) |
EXHAUST MANIFOLD TO |
|||
|
8.5 (87, 75 in.*lbf) |
||||
|
x6 |
HEAD LH GASKET |
|||
|
10 (102, 7) |
IGNITION COIL ASSEMBLY |
|||
|
21 (214, 15) |
x6 |
EM |
||
|
EXHAUST MANIFOLD |
10 (102, 7) |
|||
|
SUB-ASSEMBLY RH |
IGNITION COIL ASSEMBLY |
|||
|
NO. 2 IDLER |
34 (347, 25) |
|||
|
PULLEY SUB- |
NO. 2 MANIFOLD |
|||
|
ASSEMBLY (RR |
||||
|
STAY |
||||
|
SIDE) |
||||
|
EXHAUST MANIFOLD |
||||
|
SUB-ASSEMBLY LH |
||||
|
43 (438, 32) |
PLATE |
|||
|
V-RIBBED BELT TENSIONER |
||||
|
21 (214, 15) |
ASSEMBLY |
|||
|
WATER PUMP PULLEY |
||||
|
43 (438, 32) |
||||
|
43 (438, 32) |
||||
|
PLATE |
NO. 2 IDLER PULLEY |
|||
|
SUB-ASSEMBLY (FR SIDE) |
||||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
||||
|
Non-reusable part |
||||
|
A134941E01 |
|
EM–22 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
21 (214, 15) |
INTAKE MANIFOLD |
||||
|
NO. 2 ENGINE MOUNTING |
x4 |
x6 |
NO. 2 INTAKE MANIFOLD |
||
|
STAY RH |
|||||
|
TO HEAD GASKET |
|||||
|
20 (200, 14) |
|||||
|
NO. 1 INTAKE MANIFOLD |
ENGINE COOLANT |
||||
|
TEMPERATURE |
|||||
|
TO HEAD GASKET |
SENSOR |
||||
|
RADIO SETTING |
RADIO SETTING |
||||
|
CONDENSER |
|||||
|
CONDENSER |
|||||
|
10 (102, 7) |
GASKET |
||||
|
10 (102, 7) |
|||||
|
NO. 1 ENGINE |
20 (204, 15) |
||||
|
EM |
|||||
|
HANGER |
NO. 2 |
||||
|
KNOCK CONTROL |
ENGINE |
||||
|
HANGER |
|||||
|
SENSOR |
|||||
|
33 (337, 24) |
83 (846, 61) |
||||
|
33 (337, 24) |
|||||
|
x8 |
|||||
|
DRIVE PLATE |
|||||
|
SPACER REAR |
|||||
|
6.0 (61, 53 in.*lbf) |
DRIVE PLATE |
||||
|
NO. 2 TIMING GEAR COVER |
SPACER FRONT |
||||
|
DRIVE PLATE |
|||||
|
AND RING GEAR |
|||||
|
SUB-ASSEMBLY |
|||||
|
21 (214, 15) |
OIL LEVEL GAUGE |
||||
|
ENGINE OIL PRESSURE |
|||||
|
54 (551, 40) |
SWITCH ASSEMBLY |
21 (214, 15) |
|||
|
x3 |
O-RING |
||||
|
x2 |
NO. 2 OIL LEVEL |
||||
|
GAUGE GUIDE |
|||||
|
NO. 1 ENGINE MOUNTING BRACKET FRONT LH |
21 (214, 15) |
||||
|
N*m (kgf*cm, ft.*lbf) : Specified torque |
NO. 1 OIL LEVEL GAUGE GUIDE |
||||
|
Non-reusable part |
O-RING |
||||
|
Precoated Part |
|||||
|
A134942E01 |
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–23 |
REMOVAL
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3.PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE FRONT WHEELS
5.REMOVE ENGINE UNDER COVER LH
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE FRONT FENDER APRON SEAL RH
8.DRAIN ENGINE OIL (See page LU-4)
9.DRAIN ENGINE COOLANT (See page CO-5)
|
10. DRAIN AUTOMATIC TRANSAXLE FLUID (See page |
EM |
|
AX-207) |
11.REMOVE WINDSHIELD WIPER LINK ASSEMBLY
See page WW-9.
12.REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-481)
13.REMOVE COOL AIR INTAKE DUCT SEAL
(a)Remove the 7 clips and intake duct seal.
14.REMOVE V-BANK COVER SUB-ASSEMBLY
(a)Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.
15.REMOVE V-RIBBED BELT (See page EM-6)
|
EM–24 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
16.REMOVE AIR CLEANER INLET ASSEMBLY
(a)Remove the 2 bolts, clamp and air cleaner inlet.
17.REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-503)
18.REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a)Disconnect the vacuum hose and hose clamp.
(b)Remove the 3 bolts and air cleaner case.
19.REMOVE NO. 1 AIR CLEANER INLET
(a)Remove the bolt and No. 1 air cleaner inlet.
20.REMOVE BATTERY
(a)Loosen the bolt and nut, and remove the battery clamp.
(b)Remove the battery and battery tray.
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–25 |
21.REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
(a)Remove the clip, bolt and intake air resonator.
22.REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a)Remove the bolt, 2 nuts, and No. 2 mounting stay RH.
EM
23.REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY
(a)Remove the 4 bolts and engine moving control rod.
24.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
(a)Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
25.DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE
(a)Remove the clamp and disconnect the check valve to brake booster hose.
|
EM–26 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
26.REMOVE RADIATOR HOSE INLET
(a)Remove the clamp and disconnect the radiator hose inlet.
|
27. REMOVE RADIATOR HOSE OUTLET |
|
(a) Remove the clamp and disconnect the radiator hose |
|
outlet. |
|
EM |
|
A132980 |
28.DISCONNECT NO. 1 OIL COOLER INLET HOSE
(a)Remove the clamp and disconnect the oil cooler inlet hose.
29.DISCONNECT NO. 1 OIL COOLER OUTLET HOSE
(a)Remove the clamp and disconnect the oil cooler outlet hose.
30.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose.
31.DISCONNECT HEATER OUTLET WATER HOSE
(a)Disconnect the heater outlet water hose.
32.REMOVE ECM
HINT:
See page ES-518.
33.REMOVE RELAY BLOCK COVER UPPER
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–27 |
34.DISCONNECT ENGINE WIRE
(a)Disconnect the engine wire from the engine room junction block.
(1)Remove the nut and separate the wire harness.
(2)Using a screwdriver, unlock the engine room J/ B. Pull the engine room J/B upward.
(3)Disconnect the engine wire connectors.
(b) Remove the 2 bolts and 2 clamps from the body.
EM
(c) Remove the bolt and clamp from the bracket.
35.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a)Remove the clip and nut, and separate the cable from the transaxle.
|
EM–28 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
36. SEPARATE FUEL TUBE SUB-ASSEMBLY |
|||
|
(a) Remove the No. 1 fuel pipe clamp. |
|||
|
A129626 |
|||
|
(b) Disconnect the connector from the tube while |
|||
|
A |
pinching part A with your fingers as shown in the |
||
|
illustration. |
|||
|
NOTICE: |
|||
|
• Check for contamination in the pipe and |
|||
|
around the connector. Clean if necessary and |
|||
|
EM |
then disconnect the connector. |
||
|
A |
• Disconnect the connector by hand. |
||
|
• Do not bend, fold or rotate the nylon tube. |
|||
|
B012941E15 |
• If the pipe and connector are stuck together, |
||
|
push and pull the connector until it becomes |
|||
|
free. |
|||
|
• Put the pipe and connector ends in vinyl bags |
|||
|
to prevent damage and contamination. |
37.DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a)Disconnect the No. 1 oil reservoir to pump hose.
38.DISCONNECT RETURN TUBE SUB-ASSEMBLY
(a)Disconnect the return tube sub-assembly.
39.REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-3)
40.REMOVE EXHAUST PIPE ASSEMBLY FRONT (See page EX-2)
41.REMOVE FRONT AXLE HUB NUT LH (See page DS- 7)
42.REMOVE FRONT AXLE HUB NUT RH
HINT:
Use the same procedures described for the LH side.
43.DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See page DS-7)
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–29 |
||||
|
44. |
DISCONNECT FRONT STABILIZER LINK ASSEMBLY |
||||
|
RH |
|||||
|
HINT: |
|||||
|
Use the same procedures described for the LH side. |
|||||
|
45. |
DISCONNECT FRONT SPEED SENSOR LH (See page |
||||
|
DS-7) |
|||||
|
46. |
DISCONNECT FRONT SPEED SENSOR RH |
||||
|
HINT: |
|||||
|
Use the same procedures described for the LH side. |
|||||
|
47. |
DISCONNECT TIE ROD ASSEMBLY LH (See page |
||||
|
DS-8) |
|||||
|
48. |
DISCONNECT TIE ROD ASSEMBLY RH |
||||
|
HINT: |
|||||
|
Use the same procedures described for the LH side. |
|||||
|
49. |
DISCONNECT FRONT SUSPENSION LOWER NO. 1 |
||||
|
ARM LH (See page DS-8) |
|||||
|
EM |
|||||
|
50. |
DISCONNECT FRONT SUSPENSION LOWER NO. 1 |
||||
|
ARM RH |
|||||
|
HINT: |
|||||
|
Use the same procedures described for the LH side. |
|||||
|
51. |
SEPARATE FRONT AXLE ASSEMBLY LH (See page |
||||
|
DS-8) |
|||||
|
52. |
SEPARATE FRONT AXLE ASSEMBLY RH |
||||
|
HINT: |
|||||
|
Use the same procedures described for the LH side. |
|||||
|
53. |
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET |
||||
|
(a) Remove the No. 1 exhaust pipe support bracket |
|||||
|
with the 2 bolts. |
|||||
|
54. |
REMOVE DRIVE PLATE AND TORQUE CONVERTER |
||||
|
CLUTCH SETTING BOLT (See page AX-211) |
|||||
|
55. |
DISCONNECT STEERING SLIDING YOKE (See page |
||||
|
PS-40) |
56.REMOVE GENERATOR ASSEMBLY (See page CH-14)
57.SEPARATE COOLER COMPRESSOR ASSEMBLY
(a)Remove the 2 connector clamps.
(b)Remove the 4 bolts and separate the compressor. HINT:
Hang up the hoses instead of detaching them.
58.REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a)Set the engine lifter.
|
EM–30 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
(b)Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH.
(c)Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
(d)Operate the engine lifter, then remove the engine assembly from the vehicle.
NOTICE:
Make sure that the engine is clear of all wiring and hoses.
59.REMOVE VANE PUMP ASSEMBLY
(a)Disconnect the power steering oil pressure switch connector.
(b)Remove the pressure feed tube clamp bolt.
(c)Loosen the bolt A.
(d)Remove the bolt B and vane pump.
|
RH side : |
LH side : |
60. INSTALL ENGINE HANGERS |
|
|
(a) Install the 2 engine hangers with the 4 bolts as |
|||
|
shown in the illustration. |
|||
|
Part No.: |
|||
|
No. 1 |
No. 1 Engine hanger 12281-31070 |
||
|
No. 2 |
No. 2 Engine hanger 12282-31050 |
||
|
Bolts 91671-10825 |
|||
|
Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) |
|||
|
(b) Attach the engine sling device and hang the engine |
|||
|
A129635E03 |
with the chain block. |
||
|
61. REMOVE FRONT FRAME ASSEMBLY |
|||
|
(a) Disconnect the connector and clamp. |
|||
|
A132990 |
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–31 |
|
(b) Disconnect the 2 clamps. |
|||
|
A132989 |
|||
|
RH Side: |
LH Side: |
(c) Remove the 2 nuts and disconnect the engine |
|
|
mounting insulators RH and LH. |
|||
EM
|
A078403E05 |
|||
|
(d) Remove the bolt and disconnect the engine |
|||
|
mounting insulator FR. |
|||
|
62. |
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See |
||
|
page DS-9) |
|||
|
63. |
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See |
||
|
page DS-9) |
|||
|
64. |
REMOVE ENGINE WIRE |
||
|
A132988 |
65. |
REMOVE STARTER ASSEMBLY (See page ST-141) |
|
|
66. |
REMOVE AUTOMATIC TRANSAXLE ASSEMBLY |
||
|
HINT: |
|||
|
See page AX-207. |
|||
|
67. |
REMOVE DRIVE PLATE AND RING GEAR SUB- |
||
|
ASSEMBLY (See page EM-12) |
|||
|
68. |
SECURE ENGINE |
||
|
(a) Secure the engine onto an engine stand with the |
|||
|
bolts. |
|||
|
69. |
REMOVE INTAKE AIR SURGE TANK ASSEMBLY |
||
|
(b) |
(a) Disconnect the 2 water by-pass hoses from the |
||
|
throttle with motor body assembly. |
|||
|
(c) |
(b) Disconnect the vapor feed hose. |
||
|
(c) Disconnect the throttle with motor body assembly |
|||
|
(a) |
|||
|
connector and clamp. |
|||
|
(d) Disconnect the No. 1 ventilation hose. |
|||
|
(a) |
(c) |
||
|
A129464E01 |
|
EM–32 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
||
|
(e) Remove the bolt and vacuum hose clamp. |
|||
A129466
(f) Disconnect the connector.
(g) Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket.
EM
A129467
|
(h) |
(h) |
|
|
(h) |
(h) |
(i) |
|
(i) |
||
|
A139209E01 |
(h)Using a 5 mm socket hexagon wrench, remove the 4 bolts.
(i)Remove the 2 nuts and intake air surge tank.
(j)Remove the gasket from the intake air surge tank.
70.REMOVE IGNITION COIL ASSEMBLY
(a)Remove the 6 bolts and 6 ignition coils.
71.REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a)Remove the bolt and No. 2 engine mounting stay RH.
72.REMOVE INTAKE MANIFOLD
(a)Uniformly loosen and remove the 6 bolts and 4 nuts.
(b)Remove the intake manifold and 2 gaskets.
73.REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a)Disconnect the A/F sensor connector clamp.
(b)Uniformly loosen and remove the 6 nuts.
(c)Remove the manifold and gasket.
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–33 |
74.REMOVE OIL LEVEL GAUGE GUIDE SUBASSEMBLY
(a)Remove the oil level gauge.
(b)Remove the 2 bolts, oil level gauge guides No. 1 and No. 2.
(c)Remove the O-rings from the oil level gauge guide.
75.REMOVE NO. 2 MANIFOLD STAY
(a)Remove the 2 bolts and No. 2 manifold stay.
EM
76.REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a)Remove the 3 bolts and No. 2 insulator.
77.REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a)Uniformly loosen and remove the 6 nuts.
(b)Remove the manifold and gasket.
78.REMOVE ENGINE MOUNTING BRACKET RH
(a)Remove the 3 bolts and engine mounting bracket RH.
|
EM–34 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
79.REMOVE DRIVE SHAFT BEARING BRACKET
(a)Remove the 3 bolts and drive shaft bearing bracket.
80.REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a)Remove the 5 bolts and V-ribbed belt tensioner assembly.
81.REMOVE NO. 2 TIMING GEAR COVER
(a)Remove the 2 bolts and No. 2 timing gear cover.
|
FR Side: |
|
RR Side: |
|
A129645E01 |
82.REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a)Remove the bolt, plate and No. 2 idler pulley subassembly.
83.REMOVE WATER PUMP PULLEY (See page CO-8)
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–35 |
84.REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a)Remove the 6 bolts and No. 1 engine mounting bracket front LH.
85.REMOVE RADIO SETTING CONDENSER
(a)Remove the 2 bolts and 2 radio setting condensers.
EM
86.REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
(a)Remove the bolt and No. 1 vacuum switching valve.
87.REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a)Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
88.REMOVE KNOCK CONTROL SENSOR (See page ES511)
|
EM–36 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
89.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a)Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.
|
INSPECTION |
||
|
1. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH |
||
|
(a) Using a precision straightedge and feeler gauge, |
||
|
measure the warpage on the contact surface of the |
||
|
cylinder head. |
||
|
Maximum warpage: |
||
|
EM |
0.7 mm (0.028 in.) |
|
|
HINT: |
||
|
A134936 |
The maximum allowable warpage of each |
|
|
installation surface is 0.3 mm (0.012 in.). |
||
|
If the warpage is greater than the maximum, replace |
||
|
the manifold. |
2.INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a)Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage:
0.7mm (0.028 in.)
HINT:
The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).
If the warpage is greater than the maximum, replace the manifold.
3.INSPECT INTAKE AIR SURGE TANK ASSEMBLY
(a)Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the intake manifold.
Maximum warpage:
2.5mm (0.098 in.)
If the warpage is greater than the maximum, replace the surge tank.
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–37 |
|
4. |
INSPECT INTAKE MANIFOLD |
|
|
Cylinder head side: |
(a) |
Cylinder head side: |
|
(1) Using a precision straightedge and feeler |
||
|
gauge, measure the surface contacting the |
||
|
cylinder head for warpage. |
||
|
Maximum warpage: |
||
|
0.1 mm (0.003 in.) |
||
|
If the warpage is greater than the |
||
|
maximum, replace the intake manifold. |
||
|
(b) |
Surge tank side: |
|
|
Surge tank side: |
(1) Using a precision straightedge and feeler |
|
|
gauge, measure the surface contacting the |
||
|
surge tank for warpage. |
||
|
Maximum warpage: |
||
|
0.1 mm (0.003 in.) |
||
|
If the warpage is greater than the |
||
|
maximum, replace the intake manifold. |
||
|
EM |
||
|
A134934E01 |
||
|
INSTALLATION |
||
|
1. INSTALL ENGINE COOLANT TEMPERATURE |
||
|
SENSOR |
||
|
(a) Using a 19 mm deep socket wrench, install the |
||
|
engine coolant temperature sensor and a new |
||
|
gasket. |
||
|
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) |
||
|
2. INSTALL KNOCK CONTROL SENSOR (See page ES- |
||
|
A129648 |
511) |
|
3.INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
|
Adhesive |
(a) Clean the threads of the oil pressure switch. Apply |
|
adhesive to 2 or 3 threads of the oil pressure switch. |
|
|
Adhesive: |
|
|
Part No. 08833-00080 THREE BOND 1344, |
|
|
LOCTITE 242 or equivalent |
P012478E01
(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTICE:
Do not start the engine within 1 hour after installation to prevent oil leaks.
A129647
|
EM–38 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
4.INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
(a)Install the bolt and No. 1 vacuum switching valve.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
|
5. INSTALL RADIO SETTING CONDENSER |
|
(a) Install the 2 bolts and 2 radio setting condensers. |
|
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) |
|
EM |
|
A132991 |
6.INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a)Install the No. 1 engine mounting bracket front LH with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
7.INSTALL WATER PUMP PULLEY (See page CO-10)
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–39 |
|
FR Side: |
8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY |
|
(a) Install the No. 2 idler pulley sub-assembly and cover |
|
|
plate with the bolt. |
|
|
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) |
|
|
RR Side: |
|
|
EM |
|
|
A129645E01 |
9.INSTALL NO. 2 TIMING GEAR COVER
(a)Install the No. 2 timing gear cover with the 2 bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
|
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY |
||||
|
(a) Temporarily install the V-ribbed belt tensioner with |
||||
|
A |
the 5 bolts. |
|||
|
HINT: |
||||
|
B |
Each bolt length is as follows: |
|||
|
B |
1 |
A: 70 mm (2.76 in.) |
||
|
B |
||||
|
B: 33 mm (1.30 in.) |
||||
|
B |
2 |
(b) Install the V-ribbed belt tensioner by tightening the |
||
|
bolt 1 and bolt 2 in the order shown in the |
||||
|
A129644E01 |
illustration. |
|||
|
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) |
||||
|
(c) Tighten the other bolts. |
||||
|
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) |
|
EM–40 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
11.INSTALL DRIVE SHAFT BEARING BRACKET
(a)Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)
|
12. INSTALL ENGINE MOUNTING BRACKET RH |
|
(a) Install the engine mounting bracket RH with the 3 |
|
bolts. |
|
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) |
|
EM |
|
A129642 |
13.INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a)Install a new gasket as shown in the illustration.
(b)Install the exhaust manifold sub-assembly LH with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
14.INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a)Install the No. 2 insulator with the 3 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–41 |
15.INSTALL NO. 2 MANIFOLD STAY
(a)Install the No. 2 manifold stay with the 2 bolts.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
|
16. INSTALL OIL LEVEL GAUGE GUIDE SUB- |
||||
|
ASSEMBLY |
||||
|
No. 2 |
(a) |
Install 2 new O-rings to the oil level gauge guide. |
||
|
(b) |
Apply a light coat of engine oil to the O-rings. |
|||
|
(c) |
Push in the oil level gauge guide end into the guide |
|||
|
hole. |
||||
|
(d) |
Install the oil level gauge guide No. 1 with the bolt. |
EM |
||
|
No. 1 |
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) |
|||
|
(e) |
Install the oil level gauge guide No. 2 with the bolt. |
|||
|
A129638E01 |
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) |
|||
|
(f) |
Install the oil level gauge. |
17.INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a)Install a new gasket as shown in the illustration.
(b)Install the exhaust manifold sub-assembly RH with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
18.INSTALL INTAKE MANIFOLD
(a)Set a new gasket on each cylinder head.
NOTICE:
•Align the port holes of the gasket and cylinder head.
•Make sure that the gasket is installed in the correct direction.
(b)Set the intake manifold on the cylinder heads.
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
(c)Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
19.INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a)Install the No. 2 mounting stay RH with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
20.INSTALL IGNITION COIL ASSEMBLY
(a)Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
21.INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTICE:
DO NOT apply oil to the bolts as listed below
|
Tightening Parts |
Torque |
QTY |
|
|
N*m (kgf*cm, ft.*lbf) |
|||
|
Surge Tank and Intake Manifold |
18 (184, 13) |
4 |
|
|
No. 1 Surge Tank Stay and Cylinder |
21 (214, 15) |
1 |
|
|
Head Cover |
|||
|
No. 1 Surge Tank Stay and Surge Tank |
21 (214, 15) |
1 |
|
|
Throttle Body Bracket and Cylinder |
21 (214, 15) |
1 |
|
|
Head Cover |
|||
|
Throttle Body Bracket and Surge Tank |
21 (214, 15) |
1 |
|
(a) Install a new gasket to the intake air surge tank.
(b)Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.
Torque: Bolt
18 N*m (184 kgf*cm, 13 ft.*lbf) Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
(c)Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(d) Connect the connector.
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–43 |
(e)Install the vacuum hose clamp with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(f)Connect the No. 1 ventilation hose.
|
A129466 |
|||
|
(g) Install the clamp and connect the throttle with motor |
|||
|
(h) |
body assembly connector. |
||
|
(h) Connect the vapor feed hose. |
|||
|
(g) |
(i) Connect the 2 water by-pass hoses to the throttle |
||
|
with motor body assembly. |
|||
|
(i) |
|||
|
22. REMOVE ENGINE STAND |
|||
|
23. INSTALL DRIVE PLATE AND RING GEAR SUB- |
EM |
||
|
(i) |
(g) |
ASSEMBLY (See page EM-13) |
|
|
24. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY |
|||
|
A129464E04 |
|||
|
HINT: |
|||
|
See page AX-214. |
25.INSTALL STARTER ASSEMBLY (See page ST-148)
26.INSTALL ENGINE WIRE
27.INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-20)
28.INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-21)
29.INSTALL FRONT FRAME ASSEMBLY
(a)Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
(b)Install the engine mounting insulator FR with the bolt.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
|
EM–44 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
(c) Connect the connector and clamp.
(d) Connect the 2 clamps.
EM
A132989
|
30. INSTALL VANE PUMP ASSEMBLY |
|||
|
(a) Install the vane pump with the 2 bolts. |
|||
|
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) |
|||
|
(b) Install the pressure feed tube clamp bolt. |
|||
|
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) |
|||
|
(c) Connect the power steering oil pressure switch |
|||
|
connector. |
|||
|
A138331 |
|||
|
B |
31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE |
||
|
B |
(a) Set the engine assembly with transaxle on the |
||
|
B |
B |
engine lifter. |
|
|
(b) Install the engine assembly to the vehicle. |
|||
|
A |
A |
(c) Install the frame side rail plates RH and LH with the |
|
|
4 bolts and 2 nuts. |
|||
|
Torque: A |
|||
|
85 N*m (867 kgf*cm, 63 ft.*lbf) |
|||
|
B |
|||
|
32 N*m (329 kgf*cm, 24 ft.*lbf) |
|||
|
D |
D |
(d) Install the front suspension member brace rear RH |
|
|
C |
C |
and LH with the 4 bolts and 2 nuts. |
|
|
Torque: C |
|||
|
85 N*m (867 kgf*cm, 63 ft.*lbf) |
|||
|
D |
D |
D |
|
|
A129634E01 |
32 N*m (329 kgf*cm, 24 ft.*lbf) |
||
|
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
EM–45 |
|
3 |
32. |
INSTALL COOLER COMPRESSOR ASSEMBLY |
|
|
(a) Temporarily install the cooler compressor with the 4 |
|||
|
2 |
bolts. |
||
|
(b) Install the compressor with the 4 bolts by tightening |
|||
|
the bolts in the order shown in the illustration. |
|||
|
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) |
|||
|
4 |
(c) Install the 2 connector clamps. |
||
|
33. |
INSTALL GENERATOR ASSEMBLY (See page CH-22) |
||
|
1 |
A132977E01 |
34. |
INSTALL STEERING SLIDING YOKE (See page PS- |
|
65) |
35.INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See page AX-218)
36.INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a)Install the No. 1 exhaust pipe support bracket with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
37.INSTALL FRONT AXLE ASSEMBLY LH (See page DS- EM
21)
38.INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
39.INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See page DS-21)
40.INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT:
Use the same procedures described for the LH side.
41.INSTALL TIE ROD ASSEMBLY LH (See page DS-21)
42.INSTALL TIE ROD ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
43.INSTALL FRONT SPEED SENSOR LH (See page DS21)
44.INSTALL FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
45.INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-22)
46.INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
47.INSTALL FRONT AXLE HUB NUT LH (See page DS22)
48.INSTALL FRONT AXLE HUB NUT RH
HINT:
Use the same procedures described for the LH side.
|
EM–46 |
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY |
|
49. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See |
|
|
page EX-4) |
50.INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See page EX-4)
51.CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a)Connect the No. 1 oil reservoir to pump hose.
52.CONNECT RETURN TUBE SUB-ASSEMBLY
(a)Connect the return tube sub-assembly.
53.CONNECT FUEL TUBE SUB-ASSEMBLY
(a)Push in the fuel tube connector to the fuel pipe until the connector makes a «click» sound.
NOTICE:
•Check for damage or contamination on the connected part of the pipe.
•Check if the pipe and the connector are securely connected by trying to pull them apart.
(b)Install the No. 1 fuel pipe clamp.
54.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a)Install the clip and nut, and connect the cable to the transaxle.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
Loading…